ESAB EMP 235ic User manual

Brand: ESAB

Model: EMP 235ic

Category: Welding System

Type: User manual

Instruction manual

0463 641 001 GB 20181220

Valid for: serial no. 821-xxx-xxxx

EMP 235ic

Multi-Process Welding Inverter

TABLE OF CONTENTS

0463 641 001 © ESAB AB 2018

SAFETY ....................................................................................................... 5

1.1 Meaning of symbols ............................................................................... 5

1.2 Safety precautions ................................................................................. 5

INTRODUCTION ......................................................................................... 8

2.1 Equipment ............................................................................................... 8

TECHNICAL DATA ..................................................................................... 9

INSTALLATION............................................................................................ 12

4.1 Location................................................................................................... 12

4.2 Lifting instructions ................................................................................. 12

4.3 Mains supply........................................................................................... 13

4.3.1 Recommended fuse sizes and minimum cable area............................ 14

OPERATION ................................................................................................ 15

5.1 Connections............................................................................................ 16

5.2 Connection of welding and return cables ............................................ 17

5.3 Polarity change....................................................................................... 17

5.4 Inserting and replacing wire.................................................................. 18

5.5 Setting the wire feed pressure .............................................................. 19

5.6 Changing the feed/pressure rollers ...................................................... 20

5.7 Shielding gas .......................................................................................... 20

5.8 Duty cycle ............................................................................................... 21

5.9 Overheating protection .......................................................................... 22

5.10 Voltage Reduction Device (VRD)........................................................... 22

CONTROL PANEL ...................................................................................... 23

6.1 How to navigate...................................................................................... 23

6.1.1 Main menu............................................................................................ 23

6.1.2 sMIG mode........................................................................................... 23

6.1.3 Manual MIG mode................................................................................ 24

6.1.4 Flux cored wire mode ........................................................................... 24

6.1.5 MMA mode ........................................................................................... 24

6.1.6 LIFT-TIG mode ..................................................................................... 24

6.1.7 Settings ................................................................................................ 25

6.1.8 User manual information ...................................................................... 25

6.1.9 How does sMIG work? ......................................................................... 25

6.1.10 Why is sMIG limited to 6 mm plate?..................................................... 25

6.1.11 Icon reference guide............................................................................. 26

6.1.12 Lift TIG operation.................................................................................. 28

MAINTENANCE .......................................................................................... 29

7.1 Routine maintenance ............................................................................. 29

7.2 Power source and wire feeder maintenance ....................................... 29

7.3 VRD periodic tests ................................................................................. 30

TABLE OF CONTENTS

0463 641 001 © ESAB AB 2018

7.4 Torch and liner maintenance................................................................. 31

TROUBLESHOOTING ................................................................................. 32

ORDERING SPARE PARTS ........................................................................ 34

DIAGRAM ............................................................................................................ 35

ORDERING NUMBERS ...................................................................................... 36

WEAR PARTS ..................................................................................................... 37

ACCESSORIES .................................................................................................. 39

REPLACEMENTS PARTS .................................................................................. 40

Rights reserved to alter specifications without notice.

1 SAFETY

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1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!

Means immediate hazards which, if not avoided, will result in

immediate, serious personal injury or loss of life.

WARNING!

Means potential hazards which could result in personal injury or loss

of life.

CAUTION!

Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual

and follow all labels, employer´s safety practices and

Safety Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety

precautions must meet the requirements that apply to this type of equipment. The following

recommendations should be observed in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment

when it is started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

1 SAFETY

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4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions

when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or

wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health

• Welders having pacemakers should consult their physician before welding.

EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to

EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your

body between the torch and work cables. Never coil the torch or work

cable around your body. Keep welding power source and cables as

far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases

away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens

and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

NOISE - Excessive noise can damage hearing

Protect your ears. Use earmuffs or other hearing protection.

1 SAFETY

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MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only

qualified people remove covers for maintenance and troubleshooting as

necessary. Reinstall panels or covers and close doors when service is

finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure that there are no inflammable

materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding.

WARNING!

Do not use the power source for thawing frozen pipes.

CAUTION!

Class A equipment is not intended for use in residential

locations where the electrical power is provided by the

public low-voltage supply system. There may be

potential difficulties in ensuring electromagnetic

compatibility of class A equipment in those locations,

due to conducted as well as radiated disturbances.

NOTE!

Dispose of electronic equipment at the recycling

facility!

In observance of European Directive 2012/19/EC on

Waste Electrical and Electronic Equipment and its

implementation in accordance with national law,

electrical and/or electronic equipment that has reached

the end of its life must be disposed of at a recycling

facility.

As the person responsible for the equipment, it is your

responsibility to obtain information on approved

collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment

for purchase. For ordering information contact your local ESAB dealer or visit us on

our website.

2 INTRODUCTION

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2 INTRODUCTION

The ESAB EMP product family is a new generation of MIG and Multi-Process

(MIG/MMA/TIG) welding power sources.

The EMP 235ic power source is designed to match the needs of the light-medium fabrication

user. It is tough, durable and portable, providing excellent arc performance across a variety

of welding applications.

The EMP features a 11cm (4.3in.) colour TFT user interface display which provides quick

and easy selection of weld process and parameters, suitable for both newly trained and

intermediate level users. For more advanced users, a number of additional functions and

features can be introduced and customized to give maximum flexibility.

Exclusive to ESAB, sMIG provides users with an excellent 'Short circuit' arc characteristic.

The EMP family connects to an input power supply range between

120V–230V,1~50/60Hz input power supplies. Input power can be supplied by mains or

generator. Incorporating a PFC (Power Factor Correction) circuit significantly increases

power efficiency.

Key features:

• Excellent multi-process welding capabilities, MIG/MMA and Lift/TIG

• Automatic recognition of input power with PFC (120V–230V)

• Large 11cm (4.3in.) high resolution, customizable user interface

• Rugged case design and internal hardware

• High grade cast aluminium wire drive system provides excellent control of drive roll

geometry ensuring smooth, precise wire feeding

• Professional high grade accessories

2.1 Equipment

Package consists of the following:

EMP series

• ESAB EMP 235ic power source

• Tweco Fusion™ 250 MIG torch, 3 m (10ft) with 0.9mm (0.035in.) Contact Tip fitted

• OTW14/30 Contact tip for 0.8 mm (0.030in.) wire (qty 2)

• OTW14/35 Contact tip for 0.9 mm (0.035in.) wire (qty 2 - 1x spare and 1x fitted)

• OTW14/40 Contact tip for 1.0 mm (0.040in.) wire (qty 2)

• Comet Professional Argon Regulator/Flowmeter

• Gas hose, 4.5 m (15ft), Quick connector, 5/8-18UNF

• MMA welding cable kit 3 m (10ft)

• Return cable kit 3m (10ft)

• OK 12.50 0.9mm (0.035in.) × 5 kg (11lb) spool

• Drive roll 0.9 / 1.2mm (0.035in. / 0.045in.) V Groove (fitted)

• Drive roll 0.8 / 1.0mm (0.030in. / 0.040in.) V Groove (spare)

• Drive roll 0.8 / 0.9mm (0.030in. / 0.035in.) V Knurled (spare)

• Guide tube 1.0 mm – 1.2 mm (0.040in. / 0.045in.) (fitted)

• Guide tube 0.6 mm – 0.8 mm (0.023in. / 0.030in.) (spare)

• Key-drive shaft crescent x 2

• Mains cable 3 m (10ft) fixed with plug

• USB with Instruction manual

• Material thickness guide

3 TECHNICAL DATA

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3 TECHNICAL DATA

EMP 235ic, 230 V

Voltage 230 V, 1~ 50/60 Hz

Primary current

max.

GMAW - MIG

32.1 A

max.

GTAW - TIG

24.9 A

max.

SMAW - MMA

31.2 A

eff.

GMAW - MIG

14.6 A

eff.

GTAW - TIG

14.7 A

eff.

SMAW - MMA

14.7 A

Permissible load at GMAW - MIG

100% duty cycle 130 A / 20.50 V

50% duty cycle 170 A / 22.50 V

35% duty cycle 195 A / 23.75 V

20% duty cycle 235 A / 25.75 V

Setting range (DC) 15 A / 14.75 V – 235A/26.0V

Permissible load at GTAW - TIG

100% duty cycle 160 A / 16.4 V

50% duty cycle 200 A / 18.0 V

35% duty cycle 235A/19.4V

Setting range (DC) 5 A / 10.2 V – 240A/19.6V

Permissible load at SMAW - MMA

100% duty cycle 110 A / 24.4 V

50% duty cycle 150 A / 26.0 V

35% duty cycle 175A/27V

20% duty cycle 210 A / 28.4 V

Setting range (DC) 16 A / 20.6 V – 210A/28.4V

Open circuit voltage (OCV)

VRD activated <35 V DC

VRD deactivated, nominal OCV (Boost OCV) 68 V / (90 V)

Efficiency 86%

Power factor 0.98

Wire feed speed 2.0–17.8m/min (80–700in./min)

Wire diameter

Mild steel solid wire 0.6–1.0 mm (0.023–0.040in.)

Stainless steel solid wire 0.8–1.0 mm (0.030–0.040in.)

Flux cored wire 0.8–1.1mm (0.030–0.045in.)

Aluminium 0.8–1.2mm (0.030–3/64in.)

Bobbin size Ø 100–300 mm (4–12in.)

3 TECHNICAL DATA

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EMP 235ic, 230 V

Dimensions l×w×h 686×292×495mm (27.0×11.5×19.5in.)

Weight 28.6 kg (63 lb)

Operating temperature -10to+40°C (+14 to +104°F)

Enclosure class IP23S

Application classification

EMP 235ic, 120 V

Voltage 120 V, 1~ 50/60 Hz

Primary current

max.

GMAW - MIG Breaker 20 A: 28.6 A

Breaker 15 A: 20.3 A

max.

GTAW - TIG

Breaker 15 A: 20.8 A

max.

SMAW - MMA

Breaker 15 A: 20.8 A

eff.

GMAW - MIG Breaker 20 A: 18.0 A

Breaker 15 A: 13.0 A

eff.

GTAW - TIG

Breaker 15 A: 14.7 A

eff.

SMAW - MMA

Breaker 15 A: 14.7 A

Permissible load at GMAW - MIG

100% duty cycle Breaker 20 A: 90 A / 18.5 V

Breaker 15 A: 75 A / 17.75 V

60% duty cycle Breaker 20 A: 110 A / 19.5 V

Breaker 15 A: 90 A / 18.5 V

40% duty cycle Breaker 15 A: 100 A / 19.0 V

25% duty cycle -

20% duty cycle Breaker 20 A: 130 A / 20.5 V

Setting range (DC) 15 A / 14.75 V – 130A/20.5V

Permissible load at GTAW - TIG

100% duty cycle 100 A / 14.0 V

60% duty cycle 120 A / 14.8 V

40% duty cycle 130 A / 15.2 V

30% duty cycle -

Setting range (DC) 5 A / 10.2 V – 200A/18.0V

Permissible load at SMAW - MMA

100% duty cycle 65 A / 22.6 V

60% duty cycle 80 A / 23.2 V

40% duty cycle 85A / 23.4V

25% duty cycle -

Setting range (DC) 16 A / 20.6 V – 130A/25.2V

Open circuit voltage (OCV)

VRD activated <35 V DC

3 TECHNICAL DATA

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EMP 235ic, 120 V

VRD deactivated, nominal OCV (Boost OCV) 68 V / (90 V)

Efficiency 84%

Power factor 0.99

Wire feed speed 2.0–17.8m/min (80–700in./min)

Wire diameter

Mild steel solid wire 0.6–1.0 mm (0.023–0.040in.)

Stainless steel solid wire 0.9–1.0 mm (0.035–0.040in.)

Flux cored wire 0.8–1.2mm (0.030–0.045in.)

Aluminium 0.8–1.2mm (0.030–3/64in.)

Bobbin size Ø 100–300 mm (4–12in.)

Dimensions l×w×h 686×292×495mm (27.0×11.5×19.5in.)

Weight 28.6 kg (63 lb)

Operating temperature -10to+40°C (+14 to +104°F)

Enclosure class IP23S

Application classification

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or

cut at a certain load without overloading. The duty cycle is valid for 40°C(104°F).

For more information see section "Duty cycle" in the OPERATION chapter.

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects or water.

Equipment marked IP 23S is intended for indoor and outdoor use; however, should not be

operated in precipitation.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

4 INSTALLATION

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4 INSTALLATION

The installation must be carried out by a professional.

CAUTION!

This product is intended for industrial use. In a domestic environment this product may

cause radio interference. It is the user's responsibility to take adequate precautions.

4.1 Location

Position the power source so that its cooling air inlets and outlets are not obstructed.

A. 100mm (4in.)

B. 100mm (4in.)

4.2 Lifting instructions

The power source can be lifted using any of the handles.

4 INSTALLATION

0463 641 001

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WARNING!

Secure the equipment - particularly

if the ground is uneven or sloping.

4.3 Mains supply

NOTE!

Mains supply requirements

This equipment complies with IEC 61000-3-12 provided that the short-circuit power is

greater than or equal to S

scmin

at the interface point between the user's supply and

the public system. It is the responsibility of the installer or user of the equipment to

ensure, by consultation with the distribution network operator if necessary, that the

equipment is connected only to a supply with a short-circuit power greater than or

equal to S

scmin

. Refer to the technical data in the TECHNICAL DATA chapter.

The supply voltage should be 230VAC±10% or 120V±10%. Too low supply voltage may

cause poor welding performance. Too high welding supply voltage will cause components to

overheat and possibly fail. Contact the local electric utility for information about the type of

electrical service available, how proper connections should be made, and inspection

required.

The welding power source must be:

• Correctly installed, if necessary, by a qualified electrician.

• Correctly earthed (electrically) in accordance with local regulations.

• Connected to the correct size power point and fuse as table below.

NOTE!

Use the welding power source in accordance with the relevant national regulations.

CAUTION!

Disconnect input power and secure employing ‘Lock-out’ / ‘Tagging’ procedures.

Ensure input power line disconnect switch is locked (lock-out/Tagging) in the ‘Open’

position BEFORE removing input power fuses. Connection/Disconnect should be

carried out by competent persons.

1. Rating plate with supply

connection data

4 INSTALLATION

0463 641 001

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4.3.1 Recommended fuse sizes and minimum cable area

WARNING!

An electrical shock or fire hazard is probable if the following electrical service guide

recommendations are not followed. These recommendations are for a dedicated

branch circuit sized for the rated output and duty cycle of the welding power source.

120 – 230 V, 1 ~ 50/60 Hz

Supply voltage 230VAC 120VAC

Input current at maximum output 32.1A 30.0A

Maximum recommended fuse* or circuit breaker rating

*Time delay fuse

33.0A 30.0A

Maximum recommended fuse or circuit breaker rating 50.0A 50.0A

Minimum recommended cord size

2.5mm

(13AWG)

2.5mm

(13AWG)

Maximum recommended extension cord length 15m (50ft) 15m(50ft)

Minimum recommended grounding conductor size

2.5mm

(13AWG)

2.5mm

(13AWG)

Supply from power generators

The power source can be supplied from different types of generators. However, some

generators may not provide sufficient power for the welding power source to operate

correctly. Generators with Automatic Voltage Regulation (AVR) or with equivalent or better

type of regulation, with rated power 8kW, are recommended.

5 OPERATION

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5 OPERATION

General safety regulations for handling the equipment can be found in the "SAFETY

PRECAUTIONS" chapter of this manual. Read it through before you start using the

equipment!

NOTE!

When moving the equipment use intended handle. Never pull the cables.

WARNING!

Rotating parts can cause injury, take great care.

WARNING!

Electric shock! Do not touch the workpiece or the welding head during operation!

WARNING!

Assure that the side panels are closed during operation.

WARNING!

Tighten the bobbin locking nut in order to prevent it from sliding off the hub.

100 mm (4in.) 200 mm (8in.), 300 mm (12in.)

5 OPERATION

0463 641 001

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5.1 Connections

Front and rear:

1. Knob for current or wire feed speed

selection

8. Polarity changeover cable

2. Display 9. Positive output [+]

3. Knob for voltage selection 10. Euro torch connection

4. Main knob for menu navigation 11. Mains cable

5. Gas outlet, optional: TIG torch 12. Mains supply switch ON/OFF

6. Torch/Remote/Spool Gun connection 13. Gas inlet, optional: TIG torch

7. Negative output [-] 14. Gas inlet for MIG/MAG/Spool Gun

5 OPERATION

0463 641 001

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Drive system diagram

1. Spool 4. Gas valves

2. Circuit breaker 5. Wire feed mechanism

3. Opening spool side door

5.2 Connection of welding and return cables

The power source has two outputs for connecting welding and return cables: a negative [-]

terminal (7) and a positive [+] terminal (9), see illustration of front and rear.

For MIG/MMA process, the output to which the welding cable is connected depends on the

type of electrode; refer to electrode packaging for information relating to the correct electrode

polarity. Connect the return cable to the remaining welding terminal on the power source.

Secure the return cable's contact clamp to the work piece and ensure that there is good

contact.

For TIG process (requires optional TIG accessories), connect the TIG torch power cable to

the negative [-] terminal (7), see illustration of front and rear. Connect the gas inlet nut from

the TIG torch to the gas outlet connector (5) located on the front of the power source.

Connect the gas inlet nut (13), on rear panel, to a regulated shielding gas supply. Connect

the work return lead to the positive [+] terminal (9), see illustration of front and rear.

5.3 Polarity change

The power source is delivered with the polarity changeover cable connected to the positive

terminal. Some wires, e.g. self-shielded cored wires, are recommended to be welded with

negative polarity. Negative polarity means that the polarity changeover cable is connected to

the negative terminal and the return cable to the positive terminal. Check the recommended

polarity for the welding wire you want to use.

The polarity can be changed by moving the polarity changeover cable to suit the applicable

welding process.

5 OPERATION

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5.4 Inserting and replacing wire

The EMP 235ic will handle bobbin sizes of 100 mm (4in.), 200 mm (8in.) and 300mm

(12in.). See TECHNICAL DATA chapter for suitable wire dimensions for each wire type.

WARNING!

Do not place or point the torch near the face, hand or body as this may result in

personal injury.

WARNING!

Risk of crushing when replacing the wire bobbin! Do not use safety gloves when

inserting the welding wire between the feed rollers.

NOTE!

Make sure the correct feed/pressure rollers are used. For more information see

appendix WEAR PARTS.

NOTE!

Remember to use the correct contact tip in the welding torch for the wire diameter

used. The torch is fitted with a contact tip for 0.8mm (0.030in.) wire. If you use

another diameter, you must change the contact tip and drive roll. The wire liner fitted

in the torch is recommended for welding with Fe and SS wires.

1. Open the spool side door.

2. Release the pressure roller arm with levering the tension screw toward you (1).

3. Lift the pressure roller arm up (2).

4. With the MIG welding wire feeding from the bottom of the spool pass the electrode

wire through the inlet guide (3), between the rollers, through the outlet guide and into

the MIG torch.

5. Re-secure the pressure roller arm and wire drive tension screw and adjust the

pressure if necessary.

6. With the MIG torch lead reasonably straight feed the wire through the MIG torch by

depressing the trigger switch.

7. Close the spool side door.

5 OPERATION

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- 19 -

Welding with aluminium wire

In order to weld aluminium using the standard supplied Fusion™ 250 MIG torch, refer to

MIG torch instruction manual for replacing standard steel conduit liner with Teflon conduit

liner.

Order the following accessories: 'U' groove drive roll 1.0mm / 1.2mm (0.040in. / 0.045in.)

and Teflon conduit liner (PTFE liner), 3m (10ft). See WEAR PARTS chapter in this manual

and WEAR PARTS chapter in Instruction manual for the Fusion™ 250 for ordering number.

5.5 Setting the wire feed pressure

Illustration A Illustration B

Start by making sure that the wire moves smoothly through the wire guide. Then set the

pressure of the wire feeder's pressure rollers. It is important that the pressure is not too

high.

To check that the feed pressure is set correctly, you can feed out the wire against an

insulated object, e.g. a piece of wood.

When you hold the welding torch approximately 6mm (¼in.) from the piece of wood

(illustration A), the feed rollers should slip.

If you hold the welding torch approximately 50 mm (2in.) from the piece of wood, the wire

should be fed out and bend (Illustration B).

5 OPERATION

0463 641 001

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5.6 Changing the feed/pressure rollers

One dual groove feed roller is supplied as standard. Change the feed roller to match the filler

metal.

NOTE!

Be sure not to lose the key that is located on the drive motor shaft. This key must

align with drive roll slot for proper operation.

1. Open the spool side door.

2. Remove the feed roll retaining screw by turning it counter-clockwise.

3. Change the feed roll.

4. Tighten the feed roll retaining screw by turning it clockwise.

5. Close the spool side door.

NOTE!

The visual wire stamp designates the wire diameter groove in use.

5.7 Shielding gas

The choice of suitable shielding gas depends on the material. Typically mild steel is welded

with mixed gas (Ar + CO

) or 100% carbon dioxide (CO

). Stainless Steel can be welded

with mixed gas (Ar + CO

) or Trimix (He + Ar + CO

). Aluminium and silicon bronze use pure

argon gas (Ar). In the sMIG mode (see section "sMIG mode" in the USER INTERFACE

chapter), the optimal welding arc with the gas used will be automatically set.

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ESAB EMP 235ic User manual

Brand: ESAB

Model: EMP 235ic

Category: Welding System

Type: User manual

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